Apparatus and method for on-process migration of industrial control and automation system across disparate network types

ABSTRACT

An apparatus includes a first network controller configured to communicate over a higher-level industrial process control network, a second network controller configured to communicate over a first lower-level industrial process control network, and a third network controller configured to communicate over a second lower-level industrial process control network. The first network controller is configured to provide first data messages from the higher-level control network to the second and third network controllers for transmission over the lower-level control networks. The second and third network controllers are configured to provide second data messages from the lower-level control networks to the first network controller for transmission over the higher-level control network. Each of the second and third network controllers is configured to provide third data messages from one of the lower-level control networks to another of the second and third network controllers for transmission over another of the lower-level control networks.

TECHNICAL FIELD

This disclosure relates generally to industrial process control andautomation systems. More specifically, this disclosure relates to anapparatus and method for on-process migration of an industrial controland automation system across disparate network types.

BACKGROUND

Industrial process control and automation systems are typically used tomonitor and control complex and potentially volatile industrialprocesses without interruption, often running without scheduled downtimefor years. Over time, a need may arise to upgrade one or more componentsin an industrial process control and automation system. This could bedue to various factors, such as the desire to obtain improvementsprovided by new products or the need to replace obsolete products oraddress support issues. It is often necessary or desirable to perform anupgrade “on-process,” meaning there are little or no interruptions ofthe control routines used by the system to control the underlyingindustrial processes. Ideally, this allows the system to continuously ornear-continuously monitor and control the underlying industrialprocesses during the upgrade.

SUMMARY

This disclosure provides an apparatus and method for on-processmigration of an industrial control and automation system acrossdisparate network types.

In a first embodiment, an apparatus includes a first network controllerconfigured to communicate over a higher-level industrial process controlnetwork, a second network controller configured to communicate over afirst lower-level industrial process control network, and a thirdnetwork controller configured to communicate over a second lower-levelindustrial process control network. The first network controller isconfigured to provide first data messages from the higher-levelindustrial process control network to the second and third networkcontrollers for transmission over the lower-level industrial processcontrol networks. The second and third network controllers areconfigured to provide second data messages from the lower-levelindustrial process control networks to the first network controller fortransmission over the higher-level industrial process control network.Each of the second and third network controllers is configured toprovide third data messages from one of the lower-level industrialprocess control networks to another of the second and third networkcontrollers for transmission over another of the lower-level industrialprocess control networks.

In a second embodiment, a method includes receiving first data messagesfrom a higher-level industrial process control network at a firstnetwork controller of an interface device. The method also includesproviding the first data messages to second and third networkcontrollers of the interface device for transmission over first andsecond lower-level industrial process control networks. The methodfurther includes receiving second data messages from the lower-levelindustrial process control networks at the second and third networkcontrollers. Moreover, the method includes providing the second datamessages to the first network controller for transmission over thehigher-level industrial process control network. The method alsoincludes receiving third data messages from one of the lower-levelindustrial process control networks at one of the second and thirdnetwork controllers. In addition, the method includes providing thethird data messages to another of the second and third networkcontrollers for transmission over another of the lower-level industrialprocess control networks.

In a third embodiment, a system includes first, second, and thirdnetwork controllers configured to communicate over first, second, andthird industrial process control networks, respectively. The system alsoincludes at least one processing device configured to provide a gatewayfunction to allow data messages to be transported between (i) the firstindustrial process control network and (ii) the second and thirdindustrial process control networks. The second and third networkcontrollers are configured to provide a bridge function to allow datamessages to be transported between (i) the second industrial processcontrol network and (ii) the third industrial process control network.In addition, the system includes a bus configured to transport the datamessages between the network controllers.

Other technical features may be readily apparent to one skilled in theart from the following figures, descriptions, and claims.

BRIEF DESCRIPTION OF THE DRAWINGS

For a more complete understanding of this disclosure, reference is nowmade to the following description, taken in conjunction with theaccompanying drawings, in which:

FIG. 1 illustrates an example on-process migration in an industrialprocess control and automation system according to this disclosure;

FIGS. 2 through 6 illustrate an example device supporting on-processmigration in an industrial process control and automation system andrelated details according to this disclosure;

FIG. 7 illustrates an example method for supporting communicationsbetween components during an on-process migration in an industrialprocess control and automation system according to this disclosure; and

FIG. 8 illustrates an example method for on-process migration in anindustrial process control and automation system according to thisdisclosure.

DETAILED DESCRIPTION

FIGS. 1 through 8, discussed below, and the various embodiments used todescribe the principles of the present invention in this patent documentare by way of illustration only and should not be construed in any wayto limit the scope of the invention. Those skilled in the art willunderstand that the principles of the invention may be implemented inany type of suitably arranged device or system.

As noted above, there is often a need or desire to upgrade one or morecomponents in an industrial process control and automation system,ideally using an “on-process” migration so that monitoring and controlof one or more underlying industrial processes is continuous ornear-continuous. However, this is often difficult to achieve when a newcontrol network is being installed that is incompatible with a legacycontrol network. For example, it may be necessary or desirable tominimize the disturbances to control devices being migrated onto the newcontrol network and control devices staying on the legacy controlnetwork. Communications between the devices ideally would be maintainedat all times to prevent the loss of control or view of the underlyingprocesses throughout the migration. In addition, it is common for amigration to occur over an extended period of time since it is typicallyrare for all devices to be scheduled for an upgrade at the same time.

In the following description, a “legacy” device refers to a device beingreplaced by a more recent, enhanced, or other device. A “legacy”protocol refers to a protocol used by a legacy device, a “legacy”interface refers to an interface that supports the use of a legacyprotocol, and a “legacy” network refers to a network that supports theuse of a legacy protocol. A “new” or “enhanced” device refers to adevice that is replacing a legacy device. An “enhanced” protocol refersto a protocol used by a new or enhanced device, an “enhanced” interfacerefers to an interface that supports the use of an enhanced protocol,and an “enhanced” network refers to a network that supports the use ofan enhanced protocol. Note that the terms “migration” and “replacement”(and their derivatives), when used with reference to a legacy device,include both a physical replacement of the legacy device with a new orenhanced device and an upgrade of the legacy device to have one or morefeatures of a new or enhanced device.

FIG. 1 illustrates an example on-process migration in an industrialprocess control and automation system according to this disclosure. Asshown in FIG. 1, an industrial process control and automation system 100is being modified during the migration to create an updated industrialprocess control and automation system 100′.

The system 100 here includes two distributed control system (DCS) nodes102-104. The DCS nodes 102-104 generally represent higher-levelcontrollers or other components in an industrial process control andautomation system. For example, the DCS nodes 102-104 could be used tooptimize the control logic used by various lower-level processcontrollers 106-116 or to interact with and use data from the processcontrollers 106-116. In particular embodiments, the DCS nodes 102-104reside at “Level 2” or higher in the Purdue model of industrial control.Each DCS node 102-104 represents any suitable structure for performinghigher-level functions in an industrial process control and automationsystem. For instance, each DCS node 102-104 could represent a computingdevice executing a WINDOWS operating system or other operating system.

The process controllers 106-116 generally represent lower-levelcontrollers that perform lower-level functions in an industrial processcontrol and automation system. For example, the process controllers106-116 could receive measurements of various characteristics of anindustrial process from a number of sensors. The process controllers106-116 could use the measurements to generate control signals for anumber of actuators in the industrial process control and automationsystem. In particular embodiments, the process controllers 106-116reside at “Level 1” in the Purdue model of industrial control. Eachprocess controller 106-116 represents any suitable structure forperforming process control functions or other lower-level functions inan industrial process control and automation system. For instance, eachprocess controller 106-116 could represent a computing device executinga real-time operating system.

In this example, the process controllers 106 and 116 denote stand-alonecontrollers, while the process controllers 108-110 and 112-114 denoteredundant pairs of controllers. In each redundant pair, one processcontroller operates in a primary mode, and another process controlleroperates in a secondary or redundant mode. When in the primary mode, aprocess controller actively monitors or controls the underlyingindustrial process(es). When in the secondary mode, a process controllercan be synchronized with the primary process controller, which allowsthe secondary process controller to take over and enter the primary modeif and when the primary process controller fails or another switchoverevent occurs (such as a user-initiated switchover). A dedicatedcommunication link 118 can be used to couple and allow synchronizationof the process controllers in a redundant configuration. Thecommunication link 118 can represent a dedicated point-to-point link andbe independent of any other communication or control network in thesystem.

Different types of control networks 120-124 are used in the system tosupport communications between controllers and other devices coupled tothe networks 120-124. The control network 120 denotes a networksupporting communications to and from the DCS nodes 102-104 or otherhigher-level components of the system. The control network 122 denotes alegacy network supporting communications to and from legacy processcontrollers 106-110 and other legacy lower-level components of thesystem. The control network 124 denotes an enhanced network supportingcommunications to and from enhanced process controllers 112-116 andother enhanced lower-level components of the system.

Each control network 120-124 represents any suitable type of industrialcontrol network. In particular embodiments, the control network 120denotes a supervisory redundant coaxial network, such as a LOCAL CONTROLNETWORK (LCN) from HONEYWELL INTERNATIONAL INC. Also, in particularembodiments, the control network 122 denotes a legacy coaxial orredundant coaxial network, such as a UNIVERSAL CONTROL NETWORK (UCN)from HONEYWELL INTERNATIONAL INC. In addition, in particularembodiments, the control network 124 denotes one or more Ethernetnetworks, such as a FAULT TOLERANT ETHERNET (FTE) network from HONEYWELLINTERNATIONAL INC.

The DCS nodes 102-104 cannot communicate and interact with the processcontrollers 106-116 directly because of the presence of the differentcontrol networks 120-124. Instead, various network interface modules(NIMs) 126-128 sit between the DCS nodes 102-104 and the processcontrollers 106-116. Each NIM 126-128 generally allows devices on onenetwork to communicate with devices on another network.

It may become necessary or desirable to migrate one or more of thelegacy process controllers 106-110 onto the enhanced control network124. In this example, the legacy process controller 110 is beingreplaced by an enhanced process controller 110′. As noted above, thiscould be due to various factors, such as the desire to obtainimprovements provided by enhanced devices or the need to replaceobsolete legacy devices or address support issues with the legacydevices.

When attempting to migrate a redundant pair of process controllers (suchas the controllers 108-110), one could simply migrate the secondarylegacy process controller 110 to an enhanced process controller 110′ onthe enhanced network 124. Later, after operation of the enhanced processcontroller 110′ is verified, the other legacy process controller 108 canbe migrated onto the enhanced network 124. The enhanced processcontroller 110′ and the legacy process controller 108 could stillcommunicate over their dedicated communication link 118 and besynchronized, but the enhanced process controller 110′ no longer has theability to communicate with other devices (such as the processcontroller 106) on the legacy control network 122 via peer-to-peercommunications. In addition, various data references used by the DCSnodes 102-104 may no longer function properly without modifications thatredirect the DCS nodes 102-104 to the enhanced process controller 110′.This breakage in data references in the DCS nodes 102-104 results in aloss of control and view over the industrial process and can makeon-process migration of devices on the control network 122 to devices onthe control network 124 virtually impossible.

In accordance with this disclosure, at least one NIM 126 is replacedwith at least one NIM 126′, which can be used to both (i) supportcommunications between a supervisory control network 120 and multiplelower-level control networks 122-124 and (ii) support communicationsbetween the multiple lower-level control networks 122-124. The NIM 126′effectively operates as a gateway with respect to the first functionsince it supports communications between multiple levels of a controland automation system. The NIM 126′ effectively operates as a bridgewith respect to the second function since it supports communicationsbetween components coupled to different networks on the same level of acontrol and automation system.

As shown in FIG. 1, the NIM 126′ includes three network controllers130-134. Each network controller 130-134 supports communications usingthe appropriate protocol over one of the control networks 120-124. Thenetwork controllers 130-134 also support the gateway and bridgefunctions of the NIM 126′. For example, the network controller 130 couldreceive data messages, identify the destinations of the data messages,and send the data messages to the network controllers 132-134 forcommunication over the appropriate control networks 122-124. The networkcontrollers 132-134 could support similar functions for sending datamessages to other network controllers for delivery to the appropriatedestinations.

The NIM 126′ supports on-process migration in a control and automationsystem across disparate control network types, such as during themigration of a system from a legacy (generally obsolete) control network122 to an enhanced control network 124. The NIM 126′ generally supportscommunications over the three disparate networks, each with a differentphysical implementation. The NIM 126′ also supports incrementalmigration by allowing interaction between higher-level components in thesystem and both legacy and enhanced devices. This allows the legacydevices to be replaced with enhanced devices over an extended period oftime. In addition, the DCS nodes 102-104 can continue to interact withan enhanced device that replaces a legacy device using the same datareferences since the NIM 126′ can be used to access both the legacydevice and the enhanced device.

Additional details regarding the use of a NIM 126′ to support on-processmigration are provided below. Note that while described as beingimplemented in a NIM, this approach could be used in any other suitabledevices, such as a network gateway or other device. Also note that whilethe NIM 128 is shown here as a standard NIM, the NIM 128 could beupgraded in the same manner as the NIM 126′ to communicate over thethree control networks 120-124. This could allow the use of a redundantpair of NIMs in the updated industrial process control and automationsystem 100′.

Although FIG. 1 illustrates one example of an on-process migration in anindustrial process control and automation system, various changes may bemade to FIG. 1. For example, various components in FIG. 1 could becombined, further subdivided, moved, or omitted and additionalcomponents could be added according to particular needs. Also, thesystem could include any number of each component shown in FIG. 1.Control and automation systems come in a wide variety of configurations,and FIG. 1 does not limit the scope of this disclosure to any particularconfiguration. In addition, FIG. 1 illustrates one example operationalenvironment in which on-process migration could be supported. Thisfunctionality could be used in any other suitable industrial processcontrol and automation system.

FIGS. 2 through 6 illustrate an example device supporting on-processmigration in an industrial process control and automation system andrelated details according to this disclosure. More specifically, FIGS. 2through 6 illustrate example implementation details of the NIM 126′supporting on-process migration. For ease of explanation, the NIM 126′in FIGS. 2 through 6 is described as being used in the system of FIG. 1.The NIM 126′ could be used in any other suitable system to supportmigration from any suitable legacy devices to any suitable enhanceddevices.

As shown in FIG. 2, the NIM 126′ includes a housing 202. The housing 202generally denotes a structure that protects, encases, or holds othercomponents of the NIM 126′. The housing 202 includes any suitablestructure in which other components can be placed. The housing 202 couldalso be formed from any suitable material(s) and in any suitable manner.In particular embodiments, the housing 202 includes a chassis into whichprinted circuit board (PCB) cards can be inserted and coupled to abackplane or other structure.

The NIM 126′ also includes the three network controllers 130-134, whichare coupled to three network physical interfaces 204-208. The networkcontroller 130 supports communications over a supervisory network 120,such as an LCN. For example, the network controller 130 can receive datafrom and transmit data to various DCS nodes 102-104 coupled to thesupervisory network 120 using at least one standard or proprietaryprotocol. The network controller 130 represents any suitable controllerfor interacting with a supervisory control network. In some embodiments,the network controller 130 includes at least one processing device 210and at least one memory 212. In particular embodiments, the networkcontroller 130 represents a K4LCN interface card from HONEYWELLINTERNATIONAL INC., with modifications made to the firmware of the cardto support various functions of the NIM 126′. The physical interface 204could represent an Ethernet port or other suitable structure configuredto be coupled to the supervisory network 120.

The network controller 132 supports communications over a legacy controlnetwork 122, such as a UCN or other coaxial network. For example, thenetwork controller 132 can receive data from and transmit data tovarious process controllers 106-110 using at least one standard orproprietary legacy protocol. The network controller 132 represents anysuitable controller for interacting with a legacy control network. Insome embodiments, the network controller 132 includes at least oneprocessing device 214 and at least one memory 216. The physicalinterface 206 could represent a coaxial cable interface or othersuitable structure configured to be coupled to the control network 122.

The network controller 134 supports communications over an enhancedcontrol network 124, such as an FTE network. For example, the networkcontroller 134 can receive data from and transmit data to variousprocess controllers 112-116 using at least one standard or proprietaryenhanced protocol. The network controller 134 represents any suitablecontroller for interacting with an enhanced control network. In someembodiments, the network controller 134 includes at least one processingdevice 218 and at least one memory 220. The physical interface 208 couldrepresent an FTE interface or other suitable structure configured to becoupled to the control network 124.

Among other things, the NIM 126′ can translate between the protocolsused by the supervisory network 120, the legacy control network 122, andthe enhanced control network 124. This allows legacy devices (such asthe process controller 108) to be used while an enhanced device (such asthe process controller 110′) is being installed, commissioned, andbrought online.

The processing device 210 controls the overall operation of the NIM126′. For example, the processing device 210 could control theoperations of the network controllers 130-132 to thereby control thetransmission and reception of data by the NIM 126′. Each processingdevice 210, 214, 218 also supports translation, address resolution, orother operations needed to support the flow of data between differentcontrol networks 120-124. For instance, the processing device 210, 214,218 of each network controller 130-134 can receive incoming datamessages at the NIM 126′, determine how specific message destinationsare to be contacted, and initiate communications to and from othernetwork controllers if needed. Each processing device 210, 214, 218includes any suitable computing or processing device, such as at leastone microprocessor, microcontroller, digital signal processor, fieldprogrammable gate array, application specific integrated circuit, ordiscrete logic device.

Each memory 212, 216, 220 stores instructions or data used, generated,or collected by its associated processing device(s). For example, eachmemory 212, 216, 220 could store software or firmware instructionsexecuted by its associated processing device(s). Each memory 212, 216,220 could also store data being transported through the NIM 126′. Eachmemory 212, 216, 220 includes any suitable volatile and/or non-volatilestorage and retrieval device(s), such as at least one random accessmemory and at least one Flash or other read-only memory.

A bus 222 facilitates communications between the network controllers130-132. For example, the bus 222 could transport data between differentcontrollers 130-132 to support the exchange of data between multiplecontrol networks 120-124. The bus 222 includes any suitable structurefor transporting data between network controllers.

A particular implementation of the network controllers 130-134 is shownin FIG. 3. As shown in FIG. 3, the network controller 130 can include amodule RAM 302, which could represent at least part of the memory 212 inthe controller 130. The network controller 130 can also include a NIMpersonality 304 and a network interface controller 306. The NIMpersonality 304 represents an application or other logic executed by theNIM 126′ to provide the desired gateway functionality. The NIMpersonality 304 could, for instance, represent the code executed by theprocessing device(s) 210 in the controller 130. The network interfacecontroller 306 supports interactions with the physical interface 204 inorder to facilitate communications over an LCN or other supervisorycontrol network 120. The network controller 130 can further include twointerfaces 308-310, which facilitate communications with the othernetwork controllers 132-134 via the bus 222. The interfaces 308-310 candenote any suitable interfaces, such as Enhanced Process NetworkInterface (EPNI) interfaces (where the network controllers 132-134 areimplemented using EPNI cards).

The network controller 132 can include a network interface controller312, which supports interactions with the physical interface 206 inorder to facilitate communications over a legacy control network 122.For example, the network interface controller 312 could represent ananalog modem that communicates over a coaxial legacy network. Thenetwork controller 132 can also include a token bus controller 314,which supports the function of network management and message processingon a UCN or other token bus. In some embodiments, the token buscontroller 314 can be placed into a so-called “promiscuous” or othermode of operation in which the token bus controller 314 is able toreceive and handle data messages with destination addresses other thanthe NIM's address (to enable routing of peer-to-peer messages notaddressed to the NIM). The network controller 132 can further includelogical link control (LLC) firmware 316, which represents code thatincludes support for the gateway and bridging functions described above.That is, the LLC firmware 316 allows the network controller 132 toexchange data with the network controllers 130, 134 in order totransport data amongst the control networks. In addition, the networkcontroller 132 can include various forms of memory 318, such asregisters on a PCB and a shared RAM (which can be accessible by othernetwork controllers).

The network controller 134 can include a network interface controller320, which supports interactions with the physical interface 208 inorder to facilitate communications over an enhanced control network 124.For example, the interface controller 320 could include a network stackand interface supporting communications over an FTE network. The networkcontroller 134 can also include logic 322 supporting various functionsrelated to the enhanced control network 124. For example, UCN interface(UCNIF) logic can help map UCN addresses associated with the controlnetwork 122 into Internet Protocol (IP) addresses associated with thecontrol network 124. Address resolution, authentication, and FTE status(heartbeat) functionality could also be used to support the use of anFTE network. A token bus controller emulator 324 emulates the functionof network management and message processing on a UCN or other token busso that the network controller 134 can interact directly with thenetwork controller 132. The network controller 134 can further includeLLC firmware 326, which represents code that supports the gateway andbridging functions described above and allows the network controller 134to exchange data with the network controllers 130-132 in order totransport data amongst the control networks. In addition, the networkcontroller 134 can include various forms of memory 328, such asregisters on a PCB and a shared RAM (which can be accessible by othernetwork controllers).

FIG. 4 illustrates example data flows between components of the NIM126′. As shown in FIG. 4, the network controller 132 includes buffers402-404, which are used to buffer data transmitted to and received fromthe control network 122. The data received from the control network 122could be destined for one or more devices in any of the control networks120-124. Similarly, the network controller 134 includes buffers 406-408,which are used to buffer data transmitted to and received from thecontrol network 124. Again, the data received from the control network124 could be destined for one or more devices in any of the controlnetworks 120-124. In addition, a first shared memory block 410 includesbuffers 412-414, which are used to buffer data transmitted to andreceived from the control network 120. Once again, the data receivedfrom the control network 120 could be destined for one or more devicesin any of the control networks 120-124. Communications with the controlnetwork 120 occur via a driver 416, the NIM personality 304 (shown hereas an application), a supervisory network LLC layer 418, and the networkinterface controller 306. The memory block 410 is shared in that it isaccessible by both network controllers 130-132. The shared memory block410 could reside within the network controller 130, such as in a sharedRAM of the network controller 130.

A second shared memory block 420 facilitates the exchange of databetween the network controllers 132-134 (and indirectly the networkcontroller 130). For example, a buffer 422 is used to buffer data goingfrom the control networks 120-122 to the control network 124, and abuffer 424 is used to buffer data going from the control network 124 tothe control networks 120-122. The NIM personality 304 could monitorthese buffers 422-424 to identify their status, but it need not processany messages contained in these buffers 422-424 that are beingtransported between the control networks 122-124. The shared memoryblock 420 could reside within the network controller 130, such as in ashared RAM of the network controller 130.

The second shared memory block 420 is also used to store a networkmanagement database 428 and a network status database 430. The networkmanagement database 428 can be used to store various information used bythe network controllers 130-134 or other components of a control andautomation system, such as information used to map different addressesin different network spaces. The network status database 430 can also beused to store various information used by the network controllers130-134 or other components of a control and automation system, such asinformation identifying the status of various components orcommunication links of the control and automation system.

In some embodiments, the NIM personality 304 can periodically request(via the network controller 132) the status of all legacy devicescoupled to the control network 122 and assigned to the NIM 126′. Forexample, this request could be sent as a UCN Type 3 data request for theAUX STATUS Service Access Point (SAP). A Read Data Response (RDR) fromeach legacy device contains the current node status of that legacydevice. These messages can be used to maintain a first Route Table inthe network management database 428 or the network status database 430.Also, the network controller 134 can listen for periodic or on-change IPmulticast or other annunciations of the node status for enhanced deviceson the control network 124. These annunciations can be used to populatea second Route Table in the network management database 428 or thenetwork status database 430.

In some embodiments, one or both of the databases 428-430 can bemaintained in multiple locations within the NIM 126′. For example, oneor more address resolution tables that identify the nodes identified onthe enhanced network 124 can be maintained in the memory of the networkcontroller 134 and copied to the second shared memory block 420 for useby the network controller 132. Similarly, the LLC layer 316 of thenetwork controller 132 can maintain a list of nodes on the controlnetwork 122 and can copy this list to the second shared memory block 420for use by the network controller 134.

Note that in this example, traffic between the control networks 120 and124 appears to pass through the network controller 132 for the controlnetwork 122. This is done so that the enhanced process controllers112-116 appear (from the perspective of DCS nodes 102-104 or otherhigher-level devices) to reside on the legacy network. This also allowsthe network controller 132 to function as the “master” for networkcommunications over the control networks 122-124. This may be beneficialsince it allows the network controller 132 to control cable swapping andtime synchronization on the control network 122 while transferring datamessages into and out of various buffers between the network controllers132-134 (where communications on the control network 124 are lesstime-stringent). However, this need not be the case.

FIG. 5 illustrates an example top-level context model 500 of a portionof a control and automation system that includes the NIM 126′. Thiscontext model 500 illustrates various communication paths used in thesystem and depicts the relationships between the NIM 126′ and otherdevices. Note that specific protocols or networks are shown in FIG. 5,such as LCN, UCN, and enhanced UCN or “EUCN” (which could represent anFTE network). However, these specific protocols are examples only.

As shown in FIG. 5, the NIM 126′ communicates with a redundant NIM 128′,which could represent the NIM 128 shown in FIG. 1 after updating toinclude the functionality as the NIM 126′. The NIM 128′ could operate inthe secondary mode to monitor and synchronize with the NIM 126′ whilethe NIM 126′ operates in the primary mode.

The NIM 126′ also communicates with various LCN nodes 502 over thesupervisory control network 120. The LCN nodes 502 could include the DCSnodes 102-104. Specific examples of LCN nodes 502 include HISTORYMODULES (HMs), APPLICATION MODULES (AMs), and UNIVERSAL STATIONS (USs)from HONEYWELL INTERNATIONAL INC.

The NIM 126′ further communicates with various legacy process manager(PM) nodes 504, logic manager (LM) nodes 506, and safety manager (SM)nodes 508 over the legacy control network 122. The PM nodes 504 couldinclude standard token bus process controllers. The LM nodes 506 couldinclude classic UCN token bus controllers. The SM nodes 508 couldinclude classic safety controllers on a UCN token bus.

In addition, the NIM 126′ communicates with various high-performanceprocess managers (HPMs) 510 over the control network 122 and enhancedHPMs (EHPMs) 512 over the control network 124. The HPM 510 hererepresents a legacy device in a redundant pair of devices (such as theprocess controller 108), while the EHPM 512 here represents an enhanceddevice in a redundant pair of devices (such as the process controller110′). The HPM 510 and EHPM 512 communicate via different controlnetworks 122-124, and the NIM 126′ supports the concurrent access tothese devices. Moreover, various ones of the nodes 504-508 often need toengage in peer-to-peer communications with the HPM 510 and the EHPM 512,and the bridging function of the NIM 126′ helps to enable thesepeer-to-peer communications.

In FIG. 5, the following data types are identified as being used betweendevices. Note that these data types are for illustration only. “UCN”traffic can denote data contained in IEEE 802.4 token bus frames, whichare passed between classic UCN nodes on the control network 122. “EUCN”traffic can denote FTE or other EUCN data contained in IEEE 802.3Ethernet frames, which are passed between FTE or other EUCN nodes on thecontrol network 124. “Routed UCN” traffic can denote messages receivedon the control network 122 and retransmitted on the control network 124.“Routed EUCN” traffic can denote messages received on the controlnetwork 124 and retransmitted on the control network 122. “UCNRedundancy” can denote messages that are passed on the control network122 between redundant legacy nodes and can be retransmitted on thecontrol network 124 as EUCN messages. “EUCN Redundancy” can denotemessages that are passed over the control network 124 between redundantenhanced nodes and can be retransmitted on the control network 122 asUCN messages. “LCN” can denote messages that are passed to and from theNIM 126′ over the control network 120.

FIG. 6 illustrates an example functional division amongst the networkcontrollers 130-134 within the NIM 126′. Note that specific protocols ornetworks are shown in FIG. 6, such as LCN, UCN, and EUCN/FTE. However,these specific protocols are examples only.

As shown in FIG. 6, the network controller 130 is implemented here usinga K4LCN interface card, and the control network 120 is accessed using anLCN token ring interface. Here, the network controller 130 provides aconsole debugger, which can be useful during development and debugging.The network controller 130 also supports quality logic testing (QLT) ofthe NIM 126′ and runs the NIM personality 304. In addition, the networkcontroller 130 provides a shared memory (such as the shared memoryblocks 410 and 420) and supports interfaces to the network controllers132-134.

The network controller 132 is implemented here using an EPNI card, andthe control network 122 is accessed using a UCN token bus modem. Here,the network controller 132 processes UCN messages, performs UCN cablestate management, and supports UCN time synchronization messaging. Theseare standard functions for UCN devices. The network controller 132 alsoroutes messages for specific enhanced devices to the network controller134 and copies multicast messages for multiple enhanced devices to thenetwork controller 134. The network controller 132 further routesreceived UCN messages to the network controller 134 for delivery overthe enhanced network 124, thereby supporting peer-to-peer communicationsvia its bridging function.

The network controller 134 is implemented here using another EPNI card,and the control network 124 is accessed using an FTE interface. Here,the network controller 134 routes messages for specific enhanced devicesover the enhanced network 124 and multicast messages for multipleenhanced devices over the enhanced network 124. The network controller134 also routes messages for the control network 120 to the networkcontroller 132. The network controller 134 further routes messages forthe control network 122 to the network controller 132, therebysupporting peer-to-peer communications via its bridging function. Inaddition, the network controller 134 supports the encapsulation of timesynchronization information, which can be used to support timesynchronization within the enhanced network 124.

Although FIGS. 2 through 6 illustrate one example of a device supportingon-process migration in an industrial process control and automationsystem, various changes may be made to FIGS. 2 through 6. For example,the specific implementations of the NIM 126′ shown here are forillustration only. Various other implementations of the NIM 126′, suchas those that couple to different types of control networks 120-126,could be supported.

FIG. 7 illustrates an example method 700 for supporting communicationsbetween components during an on-process migration in an industrialprocess control and automation system according to this disclosure. Forease of explanation, the method 700 is described with respect to the NIM126′ operating in the system of FIG. 1. However, the method 700 could beused by any suitable device and in any suitable system.

As shown in FIG. 7, first data messages are received from a supervisorycontrol network at a first network controller of a NIM at step 702. Thiscould include, for example, the network controller 130 receiving thefirst data messages from the DCS nodes 102-104 or other higher-levelcomponents over the supervisory control network 120. The first datamessages are provided to second and third network controllers of the NIMat step 704. This could include, for example, the network controller 130providing the first data messages to the network controllers 132-134 viathe memory blocks 410, 420 of the shared RAM. The first data messagesare routed over legacy and enhanced control networks at step 706. Thiscould include, for example, the network controllers 132-134 mapping theaddresses of the first data messages into suitable address spaces forthe control networks 122-124. This could also include the networkcontrollers 132-134 transmitting the first data messages to the legacyand enhanced process controllers 106-116. In this way, the NIM providesa gateway function and allows higher-level devices to transmit datamessages to lower-level devices in the control and automation system.

Second data messages are received from the legacy and enhanced controlnetworks at the second and third network controllers of the NIM at step708. This could include, for example, the network controllers 132-134receiving the second data messages from the process controllers 106-116or other lower-level components over the control networks 122-124. Thesecond data messages are provided to first network controller of the NIMat step 710. This could include, for example, the network controllers132-134 providing the second data messages to the network controller 130via the memory blocks 410, 420 of the shared RAM. The second datamessages are routed over the supervisory control network at step 712.This could include, for example, the network controller 130 transmittingthe second data messages to the DCS nodes 102-104. In this way, the NIMprovides a gateway function and allows lower-level devices to transmitdata messages to higher-level devices in the control and automationsystem.

Third data messages are received from the legacy control network or theenhanced control network at the second network controller or the thirdnetwork controller of the NIM at step 714. This could include, forexample, the network controller 132 or 134 receiving the third datamessages from the process controllers 106-110 or 112-116 over thecontrol network 122 or 124. The third data messages are provided to thethird or second network controllers of the NIM at step 716. This couldinclude, for example, the network controller 132 providing the thirddata messages to the network controller 134 (or vice versa) via thememory block 420 of the shared RAM. The third data messages are routedover the enhanced control network or the legacy control network at step718. This could include, for example, the network controller 132transmitting the third data messages to the process controllers 106-110,or the network controller 134 transmitting the third data messages tothe process controllers 112-116. In this way, the NIM provides a bridgefunction and allows lower-level devices on one control network toexchange data messages with other lower-level devices on another controlnetwork in the control and automation system.

Although FIG. 7 illustrates one example of a method 700 for supportingcommunications between components during an on-process migration in anindustrial process control and automation system, various changes may bemade to FIG. 7. For example, while shown as a series of steps, varioussteps in FIG. 7 could overlap, occur in parallel, occur in a differentorder, or occur multiple times.

FIG. 8 illustrates an example method 800 for on-process migration in anindustrial process control and automation system according to thisdisclosure. For ease of explanation, the method 800 is described withrespect to the system of FIG. 1. However, the method 800 could be usedin any suitable system.

As shown in FIG. 8, existing nodes in an industrial process control andautomation system are updated to a software release that supportson-process migration at step 802. The existing nodes represent legacynodes, such as those coupled to a legacy control network 122 or thosecoupled to the supervisory control network 120.

A first NIM in a redundant pair of NIMs is upgraded and coupled to anadvanced control network at step 804. This could include, for example,installing the network controller 134 in the NIM 126 to create the NIM126′. This could also include coupling the network controller 134 in theNIM 126′ to the control network 124. The NIM being upgraded here denotesthe backup NIM in the redundant pair. A failover is performed from anun-upgraded second NIM to the upgraded first NIM at step 806. This couldinclude, for example, causing the NIM 128 to enter the backup mode whilethe NIM 126′ enters the primary mode. The second NIM is upgraded andcoupled to the advanced control network at step 808. This could include,for example, installing the network controller 134 in the NIM 128 tocreate the NIM 128′. This could also include coupling the networkcontroller 134 in the NIM 128′ to the control network 124.

A first controller in a redundant pair of controllers is upgraded and anew personality is loaded onto the upgraded first controller at step810. This could include, for example, installing a new controller moduleand a new network interface board into the controller 110 and couplingthe new interface board to the advanced control network 124. Thecontroller being upgraded here denotes the backup controller in theredundant pair. A verification is made that the upgraded firstcontroller can synchronize with an un-upgraded second controller of theredundant pair at step 812. This could include, for example, verifyingthat the upgraded first controller 110′ (operating in the backup mode)can synchronize with the controller 108 (operating in the primary mode).If so, a failover is performed from the un-upgraded second controller tothe upgraded first controller at step 814. This could include, forexample, causing the controller 108 to enter the backup mode while thecontroller 110′ enters the primary mode. A verification is made that theun-upgraded second controller can synchronize with the upgraded firstcontroller at step 816. This could include, for example, verifying thatthe controller 108 (now operating in the backup mode) can synchronizewith the controller 110′ (now operating in the primary mode). If so, thesecond controller is upgraded and a new personality is loaded onto theupgraded second controller at step 818, and a verification is made thatthe upgraded second controller can synchronize with the upgraded firstcontroller at step 820.

Although FIG. 8 illustrates one example of a method 800 for on-processmigration in an industrial process control and automation system,various changes may be made to FIG. 8. For example, while shown as aseries of steps, various steps in FIG. 8 could overlap, occur inparallel, occur in a different order, or occur multiple times. Also,note that each NIM and controller can be upgraded either by physicallyupdating a legacy NIM or controller or by installing a new NIM orcontroller. While FIG. 8 indicates that the former option is being used,the latter option is also available. In addition, while the upgrading ofcontrollers is shown in steps 810-820, any suitable legacy device(s)could be upgraded using the technique shown in FIG. 8.

In some embodiments, various functions described in this patent documentare implemented or supported by a computer program that is formed fromcomputer readable program code and that is embodied in a computerreadable medium. The phrase “computer readable program code” includesany type of computer code, including source code, object code, andexecutable code. The phrase “computer readable medium” includes any typeof medium capable of being accessed by a computer, such as read onlymemory (ROM), random access memory (RAM), a hard disk drive, a compactdisc (CD), a digital video disc (DVD), or any other type of memory. A“non-transitory” computer readable medium excludes wired, wireless,optical, or other communication links that transport transitoryelectrical or other signals. A non-transitory computer readable mediumincludes media where data can be permanently stored and media where datacan be stored and later overwritten, such as a rewritable optical discor an erasable memory device.

It may be advantageous to set forth definitions of certain words andphrases used throughout this patent document. The terms “application”and “program” refer to one or more computer programs, softwarecomponents, sets of instructions, procedures, functions, objects,classes, instances, related data, or a portion thereof adapted forimplementation in a suitable computer code (including source code,object code, or executable code). The terms “transmit,” “receive,” and“communicate,” as well as derivatives thereof, encompasses both directand indirect communication. The term “couple” and its derivatives referto any direct or indirect connection between two or more components. Theterms “include” and “comprise,” as well as derivatives thereof, meaninclusion without limitation. The term “or” is inclusive, meaningand/or. The phrase “associated with,” as well as derivatives thereof,may mean to include, be included within, interconnect with, contain, becontained within, connect to or with, couple to or with, be communicablewith, cooperate with, interleave, juxtapose, be proximate to, be boundto or with, have, have a property of, have a relationship to or with, orthe like. The phrase “at least one of,” when used with a list of items,means that different combinations of one or more of the listed items maybe used, and only one item in the list may be needed. For example, “atleast one of: A, B, and C” includes any of the following combinations:A, B, C, A and B, A and C, B and C, and A and B and C.

While this disclosure has described certain embodiments and generallyassociated methods, alterations and permutations of these embodimentsand methods will be apparent to those skilled in the art. Accordingly,the above description of example embodiments does not define orconstrain this disclosure. Other changes, substitutions, and alterationsare also possible without departing from the spirit and scope of thisdisclosure, as defined by the following claims.

What is claimed is:
 1. An apparatus comprising: a first networkcontroller configured to communicate over a higher-level industrialprocess control network; a second network controller configured tocommunicate over a first lower-level industrial process control network;and a third network controller configured to communicate over a secondlower-level industrial process control network; wherein the firstnetwork controller is configured to provide first data messages from thehigher-level industrial process control network to the second and thirdnetwork controllers for transmission over the lower-level industrialprocess control networks; wherein the second and third networkcontrollers are configured to provide second data messages from thelower-level industrial process control networks to the first networkcontroller for transmission over the higher-level industrial processcontrol network; and wherein each of the second and third networkcontrollers is configured to provide third data messages from one of thelower-level industrial process control networks to another of the secondand third network controllers for transmission over another of thelower-level industrial process control networks.
 2. The apparatus ofclaim 1, further comprising: a first physical interface coupled to thefirst network controller and configured to be coupled to thehigher-level industrial process control network; a second physicalinterface coupled to the second network controller and configured to becoupled to the first lower-level industrial process control network; anda third physical interface coupled to the third network controller andconfigured to be coupled to the second lower-level industrial processcontrol network.
 3. The apparatus of claim 1, further comprising: afirst shared memory block configured to buffer the first and second datamessages, the first and second network controllers configured to accessthe first shared memory block.
 4. The apparatus of claim 3, furthercomprising: a second shared memory block configured to buffer at leastthe third data messages, the second and third network controllersconfigured to access the second shared memory block.
 5. The apparatus ofclaim 1, wherein: the second network controller comprises a token buscontroller configured to communicate over a token bus of the firstlower-level industrial process control network; and the third networkcontroller comprises a token bus controller emulator.
 6. The apparatusof claim 1, wherein: the second network controller comprises logicallink control (LLC) firmware configured to route the second data messagesto the first network controller and to route at least some of the thirddata messages to the third network controller; and the third networkcontroller comprises LLC firmware configured to route the second datamessages to the first network controller and to route at least some ofthe third data messages to the second network controller.
 7. Theapparatus of claim 2, wherein: the first physical interface isconfigured to be coupled to a redundant coaxial control network; thesecond physical interface is configured to be coupled to a coaxial orredundant coaxial control network; and the third physical interface isconfigured to be coupled to an Ethernet network or a redundant Ethernetnetwork.
 8. The apparatus of claim 1, wherein the apparatus isconfigured to provide control devices on the higher-level industrialprocess control network with concurrent access to control devices on thefirst and second lower-level industrial process control networks.
 9. Amethod comprising: receiving first data messages from a higher-levelindustrial process control network at a first network controller of aninterface device; providing the first data messages to second and thirdnetwork controllers of the interface device for transmission over firstand second lower-level industrial process control networks; receivingsecond data messages from the lower-level industrial process controlnetworks at the second and third network controllers; providing thesecond data messages to the first network controller for transmissionover the higher-level industrial process control network; receivingthird data messages from one of the lower-level industrial processcontrol networks at one of the second and third network controllers; andproviding the third data messages to another of the second and thirdnetwork controllers for transmission over another of the lower-levelindustrial process control networks.
 10. The method of claim 9, whereinthe interface device transports the third messages from the secondnetwork controller to the third network controller and from the thirdnetwork controller to the second network controller.
 11. The method ofclaim 9, further comprising: coupling a first physical interface of theinterface device to the higher-level industrial process control network,the first physical interface coupled to the first network controller;coupling a second physical interface of the interface device to thefirst lower-level industrial process control network, the secondphysical interface coupled to the second network controller; andcoupling a third physical interface of the interface device to thesecond lower-level industrial process control network, the thirdphysical interface coupled to the third network controller.
 12. Themethod of claim 9, further comprising: using a first shared memory blockto buffer the first and second data messages, the first and secondnetwork controllers configured to access the first shared memory block.13. The method of claim 12, further comprising: using a second sharedmemory block to buffer at least the third data messages, the second andthird network controllers configured to access the second shared memoryblock.
 14. The method of claim 9, wherein: the second network controllercomprises a token bus controller that communicates over a token bus ofthe first lower-level industrial process control network; and the thirdnetwork controller emulates a token bus controller.
 15. The method ofclaim 9, wherein: the second network controller comprises logical linkcontrol (LLC) firmware that routes the second data messages to the firstnetwork controller and routes at least some of the third data messagesto the third network controller; and the third network controllercomprises LLC firmware that routes the second data messages to the firstnetwork controller and routes at least some of the third data messagesto the second network controller.
 16. The method of claim 11, wherein:the first physical interface is coupled to a redundant coaxial controlnetwork; the second physical interface is coupled to a coaxial orredundant coaxial control network; and the third physical interface iscoupled to an Ethernet network or a redundant Ethernet network.
 17. Themethod of claim 9, further comprising: providing control devices on thehigher-level industrial process control network with concurrent accessto control devices on the first and second lower-level industrialprocess control networks using the interface device.
 18. A systemcomprising: first, second, and third network controllers configured tocommunicate over first, second, and third industrial process controlnetworks, respectively; at least one processing device configured toprovide a gateway function to allow data messages to be transportedbetween (i) the first industrial process control network and (ii) thesecond and third industrial process control networks, wherein the secondand third network controllers are configured to provide a bridgefunction to allow data messages to be transported between (i) the secondindustrial process control network and (ii) the third industrial processcontrol network; and a bus configured to transport the data messagesbetween the network controllers.
 19. The system of claim 18, wherein:the second network controller comprises: a token bus controllerconfigured to communicate over a token bus of the second industrialprocess control network; and logical link control (LLC) firmwareconfigured to route some of the data messages to the first and thirdnetwork controllers; and the third network controller comprises: a tokenbus controller emulator; and LLC firmware configured to route some ofthe data messages to the first and second network controllers.
 20. Thesystem of claim 18, further comprising: a first physical interfacecoupled to the first network controller and configured to be coupled tothe first industrial process control network; a second physicalinterface coupled to the second network controller and configured to becoupled to the second industrial process control network; and a thirdphysical interface coupled to the third network controller andconfigured to be coupled to the third industrial process controlnetwork.